Cut form blocks from 3/4" MDF. For you scratchbuilders just starting out, here's the way to do this. Plot the coordinates as carefully as you possibly can on the block material (I used 3/4" MDF). Use a sharp pencil, and keep it sharp as you're plotting to eliminate any "fudge" in the plots.On a band saw with the table set to 10 degrees (to allow for springback), saw as close to the pencil marks as you dare. Don't worry about the smooth curves in your plots at this point. Your sanding will allow you to put a nice artistic curve on the block, and still respect the coordinates. I fretted needlessly about this. I even tried to do the computer plotting thing, but just didn't have any luck. Turns out I didn't even need it.Sand close to the line with a bench sander. Use the spinning disk on the the side with the table tilted to 10 degrees (springback). You'll be amazed at how smooth and beautiful these turn out this way. Turn on your shop vac and plug it into the band saw and sander dust collection port if you can. MDF makes a very fine dust that gets EVERYWHERE.
